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Re: My 1997 Express
Dyno_Dave #724825 June 16th 2017 11:15 am
Joined: Nov 2013
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Likes: 32
pooh-bah
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pooh-bah
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The van had puked it's last A/C recharge, and I could not find anything obvious. But the black light told the tale. Dry EVERYWHERE (good news with 20 year or lines and seals everywhere front to back), except the compressor itself. It was a glowing green ball of dye. New compressor, and life is good (and chilly!).

Working with a friend to get a Tech II on the van today and change the profile back. The van has a replacement PCM, and the previous shop (prior to my purchase) lazily (IMO) left the previous vans profile in it, including I suspect improper axle ratio info. I believe a re-flash with the right profile will restore the speedo to proper operation.

Then this weekend we'll dig back into that driver door panel, and maybe add an amp, maybe even a sub if time allows. Although those are secondary to more important pre-roadtrip chores...sort of....tunes are awful important! [Linked Image]

Last edited by Dyno_Dave; June 16th 2017 11:17 am.
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Re: My 1997 Express
Dyno_Dave #724827 June 16th 2017 11:22 am
Joined: Jul 2014
Posts: 4,805
Likes: 123
Uncle Rust N Dents
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Uncle Rust N Dents
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In my experience, tunes are the most important thing. LOL


[Linked Image from farm3.staticflickr.com]
Re: My 1997 Express
Dyno_Dave #724906 June 19th 2017 12:01 am
Joined: Nov 2013
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pooh-bah
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pooh-bah
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On to the driver's door today. Didn't break anything this time, but there was plenty of other damage.

It immediately became clear that like the passenger side, someone had been in here before. The first thing I saw was this cracked hot glue repair. More an attempt to fix rattles I think.

[Linked Image]

It also became obvious this armrest pad was in much worse condition underneath.

[Linked Image]

[Linked Image]

At least a few of Humpty Dumpty's pieces are large enough to help in the repair.

[Linked Image]

As for the large panel, it needed some of the same repairs as the passenger door...a good cleaning, and a good glue repair for the broken plastic spot welds on the big pocket. However, these front door panels are NOISY! I can't get the videos to load, but you would not believe how much noise those small plastic pockets make when the panel flexes. It's crazy. Time to peel back the jute and see what we can do.

[Linked Image]

When I had to rebuild the plastic radio pod for my T/A, I padded areas that rubbed together with a very thin cloth. I'm going to use the same trick here.

[Linked Image]

[Linked Image]

Ready to go back into the panel.

[Linked Image]

Installed, with a little ribbon of dum dum for good measure.

[Linked Image]

You'll have to take my word for it since the video won't load....but this made a HUGE difference. Glue the jute back down, the the big panel is done.

[Linked Image]

Meanwhile, back on the bench...stainless washers are JB Welded into the bottom of the pad, to reinforce the areas of shattered plastic around the screw holes.

[Linked Image]

Also some weld for the cracked plastic frame.

[Linked Image]

[Linked Image]

And lots of epoxy to strengthen the bottom, and the broken plastic pieces.

[Linked Image]

[Linked Image]

The rest is pretty much the same as the other door. Tweeter installed, soldered pigtail, carpet around crossover and wiring, old blown driver removed, trimmed speaker opening on panel, previous hot glue repair re-melted, etc. Pad back on the door panel with two stainless sheet metal screws and one small machine screw.

[Linked Image]

Tomorrow I'll add the sound deadening to the door inner, install the new Alpine driver with Boom Mat baffle, and reassemble the door.


Last edited by Dyno_Dave; July 19th 2017 1:56 pm.
Re: My 1997 Express
Dyno_Dave #724909 June 19th 2017 1:36 am
Joined: Aug 2001
Posts: 12,107
Likes: 37
Maniac
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Maniac
Joined: Aug 2001
Posts: 12,107
Likes: 37
Nice work! Fixing all those little things takes time but results in a much nicer finished project.


Windows- they're what make a van worth owning!
Re: My 1997 Express
Dyno_Dave #724913 June 19th 2017 4:06 pm
Joined: Jul 2014
Posts: 4,805
Likes: 123
Uncle Rust N Dents
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Uncle Rust N Dents
Joined: Jul 2014
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I used that same JB Weld, washer fix on our truck's center door striker covers around 5 years ago, and it's been so rock solid that I forgot about until I just saw your post. smile


[Linked Image from farm3.staticflickr.com]
Re: My 1997 Express
Dyno_Dave #724928 June 19th 2017 9:20 pm
Joined: Nov 2013
Posts: 3,692
Likes: 32
pooh-bah
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pooh-bah
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Thanks Reed.

Glad to hear it's a repair that's held up for you Rusty. I hope this one does as well, but I'm going to check into ordering some new ones, or finding some good used ones (good luck to me with that), just in case.

No work on her today. Long day at work, and just now getting done with other chores, and it's pouring rain out.

Re: My 1997 Express
Dyno_Dave #724960 June 20th 2017 10:05 pm
Joined: Aug 2002
Posts: 18,522
Likes: 135
Supreme Master
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Supreme Master
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Just caught up on your latest work. Very nice.


[Linked Image from i.imgur.com]

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Re: My 1997 Express
Dyno_Dave #724964 June 21st 2017 7:34 am
Joined: Nov 2013
Posts: 3,692
Likes: 32
pooh-bah
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pooh-bah
Joined: Nov 2013
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Thanks lukester. Very anxious to get back on it, and get the driver's door buttoned back up, but work has been conspiring against me this week.

Re: My 1997 Express
Dyno_Dave #724986 June 22nd 2017 7:59 am
Joined: Nov 2013
Posts: 3,692
Likes: 32
pooh-bah
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pooh-bah
Joined: Nov 2013
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Likes: 32
Finally got a break on work, weather, fife, and was able to spend a few hours on the van last night. As all the sub-assemblies were ready to go, things went very smoothly.

Sound deadening pads (4) installed inside the door, water shield back in place.

[Linked Image]

Boom Mat baffle installed to the speaker pod, Alpine speaker installed, electrical connector wrapped in carpet.

[Linked Image]

Foam lip seal added to edge of speaker.

[Linked Image]

And the driver door is all back together. Everything works, far fewer squeaks and rattles.

[Linked Image]

The door pull is rock solid. And that tiny little smooth stainless screw head is all that there is to tell you anything was done.

[Linked Image]

After having my new General Grabbers for a week or more, I finally got around to scrubbing the soap off of them. Chrome stems, stick on weights all on the back. A little too late to save the lip from weight corrosion, but why do more damage? I hope these wheels are a year or so stop gap. I still want those Hurst wheels I posted before.

[Linked Image]

My daughters H.S. graduation was a few weeks back. It was held at an outdoor amphitheater, and it was COLD. The theater was selling real Mexican blankets (made in Mexico and not China), and when one option was a blue/white/silver grey one, well, that just had to be a sign, right? grin

[Linked Image]

Last edited by Dyno_Dave; July 19th 2017 2:00 pm.
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